System and method for inspecting fasteners

ABSTRACT

A fastener probe assembly includes a disc configured to rotate about a first axis of a fastener, an ultrasound probe coupled to the disc, and an encoder configured to determine an orientation of the ultrasound probe relative to the first axis of the fastener during an inspection of the fastener. The ultrasound probe is configured to interface with an axial end of the fastener, to emit ultrasound signals into the axial end of the fastener, and to receive ultrasound signals from the fastener.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of, and claims priority to, U.S.application Ser. No. 14/846,238, entitled “SYSTEM AND METHOD FORINSPECTING FASTENERS,” filed Sep. 4, 2015, which claims priority fromU.S. Provisional Application Ser. No. 62/046,678, entitled “SYSTEM ANDMETHOD FOR INSPECTING FLANGE FASTENERS,” filed Sep. 5, 2014, which arehereby incorporated by reference in their entireties.

BACKGROUND

The subject matter disclosed herein relates to non-destructiveinspection, and more specifically to a system and method for inspectionof fasteners of a hydrocarbon extraction system.

Components of the hydrocarbon extraction systems may be located inonshore, offshore, subsea, or subterranean environments. Hydrocarbonextraction systems convey various fluids between components via tubularmembers. The conveyed fluids may be pressurized relative to the externalenvironment of the components or other tubular members. Some componentsof the hydrocarbon extraction system are coupled to one another viaflange connections. The components and flange connections are subjectedto various loads and environmental conditions during operation in thehydrocarbon extraction system. Some components may be utilized withanother hydrocarbon extraction system if the components pass aninspection and satisfy known standards. Unfortunately, traditionalinspection methods involve disassembling components and flangeconnections, which can be expensive and time consuming. Additionally,repeated assembly and disassembly may increase wear on components andthe flange connections.

BRIEF DESCRIPTION

Certain embodiments commensurate in scope with the present disclosureare summarized below. These embodiments are not intended to limit thescope of the claim, but rather these embodiments are intended only toprovide a brief summary of the present disclosure. Indeed, embodimentsof the present disclosure may encompass a variety of forms that may besimilar to or different from the embodiments set forth below.

In a first embodiment, a fastener probe assembly includes a discconfigured to rotate about a first axis of a fastener, an ultrasoundprobe coupled to the disc, and an encoder configured to determine anorientation of the ultrasound probe relative to the first axis of thefastener during an inspection of the fastener. The ultrasound probe isconfigured to interface with an axial end of the fastener, to emitultrasound signals into the axial end of the fastener, and to receiveultrasound signals from the fastener.

In another embodiment, a system includes a probe assembly and acontroller coupled to the probe assembly. The probe assembly includes ahousing and one or more probes. The probe assembly is configured to becoupled to a fastener of an assembled connection, and the housing isconfigured to at least partially receive an axial end of the fastener.The controller is configured to control an ultrasound inspection of thefastener. The ultrasound inspection includes emitting ultrasound signalsfrom the one or more probes of the probe assembly into the axial end ofthe fastener, receiving ultrasound signals with the one or more probesof the probe assembly, and comparing the received ultrasound signals tobaseline data for the fastener.

In another embodiment, an inspection method includes coupling a probeassembly to a fastener of an assembled connection of an assembled stackof components, emitting ultrasound signals from the fastener probeassembly into an axial end of the fastener, receiving ultrasound signalsat the fastener probe assembly, and generating inspection datacorresponding to the fastener based at least in part on the receivedultrasound signals. The housing of the probe assembly is configured toat least partially receive the fastener. The received ultrasound signalsare reflected from the fastener.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the presentdisclosure will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a block diagram of an embodiment of a hydrocarbon extractionsystem with some components coupled via flange connections;

FIG. 2 is a cross-sectional view of an embodiment of a stack of ahydrocarbon extraction system with flange connections;

FIG. 3 is a cross-sectional view of an embodiment of a flange seal of aflange connection, taken along line 3-3 of FIG. 2;

FIG. 4 is a block diagram of embodiments of probe assemblies and aflange connection;

FIG. 5 is a perspective view of an embodiment of a fastener probeassembly and fastener studs of a flange connection;

FIG. 6 is a perspective view of an embodiment of the fastener probeassembly;

FIG. 7 is a cross-sectional view of an embodiment of the fastener probeassembly and a fastener; and

FIG. 8 is a cross-sectional view of an embodiment of a fastener probeassembly and a fastener bolt of a flange connection; and

FIG. 9 is an embodiment of a method for inspecting fasteners of anassembled flange connection.

DETAILED DESCRIPTION

One or more specific embodiments of the present disclosure will bedescribed below. In an effort to provide a concise description of theseembodiments, all features of an actual implementation may not bedescribed in the specification. It should be appreciated that in thedevelopment of any such actual implementation, as in any engineering ordesign project, numerous implementation-specific decisions must be madeto achieve the developers' specific goals, such as compliance withsystem-related and business-related constraints, which may vary from oneimplementation to another. Moreover, it should be appreciated that sucha development effort might be complex and time consuming, but wouldnevertheless be a routine undertaking of design, fabrication, andmanufacture for those of ordinary skill having the benefit of thisdisclosure.

When introducing elements of various embodiments of the presentdisclosure, the articles “a,” “an,” “the,” and “said” are intended tomean that there are one or more of the elements. The terms “comprising,”“including,” and “having” are intended to be inclusive and mean thatthere may be additional elements other than the listed elements.

A hydrocarbon extraction system 10 is illustrated in FIG. 1. Thehydrocarbon extraction system 10 facilitates extraction of a hydrocarbonresource, such as oil or natural gas, from a well 12. The hydrocarbonextraction system 10 includes a variety of equipment, including surfaceequipment 14, riser equipment 16, and stack equipment 18, for extractingthe resource from the well 12 via a wellhead 20. The hydrocarbonextraction system 10 may be employed in a variety of drilling orextraction applications, including onshore and offshore, i.e., subsea,drilling applications. For example, in a subsea resource extractionapplication, the surface equipment 14 is mounted to a drilling rig abovethe surface of the water, the stack equipment 18 is coupled to thewellhead 20 proximate to the sea floor, and the surface equipment 14 iscoupled to the stack equipment 18 via the riser equipment 16.Connectors, illustrated by arrows 22, may facilitate coupling theequipment packages (e.g., surface equipment 14, riser equipment, 16,stack equipment 18, wellhead 20) of the hydrocarbon extraction system 10to one another. Additionally, or in the alternative, connectors 22 mayfacilitate coupling of components within an equipment package to oneanother. Embodiments of the connector 22 may include, but are notlimited to, an H-4® subsea connector, available from Vetco Gray ofHouston, Tex.

The various equipment portions (e.g., surface equipment 14, riserequipment 16, stack equipment 18, wellhead 20) of the hydrocarbonextraction system 10 may include a variety of components 24. Forexample, the surface equipment 14 may include a variety of devices andsystems, such as pumps, power supplies, cable and hose reels, controlunits, a diverter, a rotary table, and the like. Similarly, the riserequipment 16 may also include a variety of components, such as riserjoints, valves, control units, and sensors, among others. In someembodiments, the riser equipment 16 may include a lower marine riserpackage (LMRP). The riser equipment 16 facilitates transmission of theextracted resource to the surface equipment 14 from the stack equipment18 and the well 12. The stack equipment 18 also includes a number ofcomponents, such as one or more blowout preventers (BOPs), a subseamanifold, and/or production trees (e.g., completion or “Christmas”trees) for extracting the desired resource from the wellhead 20 andtransmitting it to the surface equipment 14 and the riser equipment 16.The desired resource extracted from the wellhead 20 is transmitted tothe surface equipment 14 generally in an upward direction 26. Asutilized herein, a downward direction 28 is hereby defined as oppositethe upward direction 26, such that the downward direction 28 is thegeneral direction from the surface equipment 14 to the well 12. As maybe appreciated, the upward direction 26 and the downward direction 28are generally parallel to an axis of each component 24.

Some of the components 24 are coupled to one another via hydrocarboncomponent fasteners (e.g., flange connections 30), thereby formingflange seals 32 between the respective components 24. The flangeconnections 30 may secure the respective components 24 together viafasteners 34 that at least partially extend through flanges 36 of one orboth components 24 of the flange connection 30. In some embodiments, acomponent 38 (e.g., blowout preventer) is coupled to a connector 40(e.g., H-4® subsea connector) via a flange connection 42.

As may be appreciated, the desired resource extracted from the wellhead20 is transferred in the upward direction 26 through the equipment ofthe hydrocarbon extraction system 10 such that the desired resource isisolated from the environment 44 (e.g., subsea environment). The flangeseals 32 enable the desired resource to be isolated from the environment44 at each flange connection 30. For example, the flange seals 32facilitate the isolation of the desired resource at a high temperatureand/or a high pressure relative to the environment 44.

Some components 24 of the hydrocarbon extraction system 10 may beutilized in other hydrocarbon extraction systems during the serviceablelife of the respective components 24. For example, upon completion ofuse of the stack equipment 18 in a first hydrocarbon extraction system10 at a first well 12, at least some of the components 24 of the stackequipment 18 may be utilized in a second hydrocarbon extraction systemat a second well. Traditionally, the components of the stack equipment18 are brought to the surface (e.g., oil rig, surface vessel) so thatthe components 24 may be disassembled from one another for inspectionand/or certification for additional service. The inspection may beperformed at a site remote from the hydrocarbon extraction system 10 andthe wellhead 20. Traditional inspections of the components 24 mayinclude penetrant testing and/or magnetic particle testing of theflanges 36, the flange seals 32, and the fasteners 34. As may beappreciated, disassembly of the flange connections 30 may be timeconsuming. Additionally, disassembly and reassembly of the flangeconnections 30 may increase wear on the flange seals 32, the fasteners34, and the flanges 36 of the components 24.

FIG. 2 is cross-sectional view of an embodiment of a portion of thestack equipment 18 of the hydrocarbon extraction system 10 of FIG. 1. Afirst component 50 of the stack equipment 18 is coupled to a secondcomponent 52 (e.g., blow out preventer (BOP)) via a flange connection54. Both the first component 50 and the second component 52 are disposedabout an axis 56 through a bore 58. In some embodiments, the firstcomponent 50 may be identified by a first identifier 51, and the secondcomponent 52 may be identified by a second identifier 53. The first andsecond identifiers 51, 53 may include, but are not limited to, serialnumbers, bar codes, radio frequency identification (RFID) tags or chips,distinguishing part geometries, or any combination thereof. In someembodiments, the first and second identifiers 51, 53 are embedded withinthe respective components 50, 52.

The bore 58 facilitates fluid communication between the wellhead 20 andthe surface equipment 14, such as for hydrocarbon flows, mud, orhydraulic fluids. A plurality of fasteners 60 (e.g., bolts, studs)extend through a flange 62 of the first component 52 and couple with asecond surface 64 of the second component 52. The flange 62 extends in acircumferential direction 66 about the bore 58, and the plurality offasteners 60 are disposed circumferentially about the axis 56 to securethe first component 50 to the second component 52. That is, theplurality of fasteners 60 may urge the first component 50 and the secondcomponent 52 towards each other such that a first surface 68 of thefirst component 50 interfaces with the second surface 64 of the secondcomponent 52.

FIG. 3 is a cross-sectional view of an embodiment of the flangeconnection 54 between the first component 50 and the second component52, taken along line 3-3 of FIG. 2. Interior surfaces 70 of the firstand second components 50, 52 form the bore 58 through the respectivecomponents 50, 52 of the assembled stack equipment 18. The first andsecond components 50, 52 may form a seal passage 72 near the interiorsurfaces 70 (e.g., around the bore 58) that extends in thecircumferential direction 66 about the interior surfaces 70. The sealpassage 72 is disposed in a radial direction 73 outside the interiorsurfaces 70. Recesses, grooves, or depressions in the first component 50and/or the second component 52 form the seal passage 72. The shape ofthe seal passage 72 may include, but is not limited to a circle, asemicircle, an ellipse, a rectangle, a pentagon, a hexagon, an octagon,and so forth. The seal passage 72 is configured to receive a seal 74,such as an elastomeric seal, O-ring, C-ring (gasket), and so forth. Asmay be appreciated, the seal 74 provides flexibility to the flangeconnection 54 that enables fluids (e.g., hydrocarbons, oils, gases,slurries) within the bore 58 to remain isolated from the externalenvironment 44 about the components 50, 52 despite some relativemovement between the first and second components 50, 52 in thecircumferential direction 66, the radial direction 73, or the axial 104.FIG. 3 illustrates an embodiment of the seal 74 with the dashedcross-section of a circular seal (e.g., O-ring). A lip portion 76 isradially disposed between the seal passage 72 and the interior surfaces70 about the bore 58. The lip portion 76 may include portions of thefirst component 50 and the second component 52. Additionally, or in thealternative, the lip portion 76 may only include portions of the firstcomponent 50, or may only include portions of the second component 52. Alip interface 78 between the first surface 68 and the second surface 64at the lip portion 76 facilitates the isolation of the bore 58 from theseal passage 72, and a body interface 80 facilitates the isolation ofthe seal passage 72 and the bore 58 from the external environment 44.

Various factors may affect the integrity and effectiveness of the flangeconnection 54 to isolate the bore 58 from the external environment 44and to secure the first component 50 to the second component 52. Thedesired strength of portions of the first and second components 50, 52is based at least in part on operating conditions of the hydrocarbonextraction system. The operating conditions may include, but are notlimited to, the composition of the extracted resource, the pressure ofthe extracted resource, the external environment, the depth of thecomponent when installed, and so forth. The strength of a component maybe affected by flaws of the interior surfaces 70, the lip portion 76,the seal passage 76, the seal 74, or any combination thereof. Flaws mayinclude, but are not limited to porosity, cracks (e.g., surface cracksor subsurface cracks), wear, or any combination thereof. Additionally,or in the alternative, flaws may affect the pressures at which theflange connection 54 between the first and second components 50, 52forms an effective seal to isolate the bore 58 from the seal passage 72and/or the external environment 44. Furthermore, flaws in the fasteners60 of the flange connection 54 may affect the magnitude and thedistribution about the axis 56 of a sealing force between the firstcomponent 50 and the second component 52.

The first and second components 50, 52 may be inspected and/or certifiedprior to utilization in a hydrocarbon extraction system 10. For example,the first and second components 50, 52 may be inspected and/or certifiedafter manufacture and prior to installation in a first hydrocarbonextraction system. After utilization of the first and second components50, 52 in the first hydrocarbon extraction system, it may be desirablefor the first and second components 50, 52 to be installed in a secondhydrocarbon extraction system. However, standards or regulations mayrequire re-inspection and/or re-certification of the first and secondcomponents 50, 52 before utilization in the second hydrocarbonextraction system. For example, re-inspection and/or re-certificationmay identify flaws (e.g., porosity, cracks, wear) of portions of thefirst and second components 50, 52. Systems and methods described hereinfacilitate inspection of portions of the first and second components 50,52 while the first and second components 50, 52 are assembled withoutdisassembly of the flange connection 54. For example, a probe assemblydiscussed herein may utilize one or more ultrasound probes to inspectportions of the assembled first and second components 50, 52 of theflange connection 54. In some embodiments, probe assemblies may utilizeone or more phased arrays of ultrasound probes. Accordingly, the probeassembly enables non-destructive testing of assembled flange connection54, thereby reducing the cost, labor, and time of assembly anddisassembly of the flange connection 54 with traditional inspectionmethods. Furthermore, a probe assembly may enable multiple componentsand multiple flange connections assembled together in series to beinspected at substantially the same time, thereby further reducing thecost, labor, and time of inspection.

FIG. 4 illustrates embodiments of a first probe assembly 100 (e.g., boreprobe assembly, flange probe assembly) and a second probe assembly 102(e.g., bolt probe assembly) that are configured to inspect portions ofthe first and second components 50, 52. The first probe assembly 100 isdisposed within the bore 58 of the first and second components 50, 52along the axis 56. The first probe assembly 100 is moved in an axialdirection 104 along the bore 58 to inspect axial portions of the firstand second components 50, 52, and the first probe assembly 100 isrotated in the circumferential direction 66 to inspect circumferentialportions of the first and second components 50, 52. One or more probes108 (e.g., ultrasound probes) coupled to a controller 110 obtaininspection data regarding portions of the first and second components50, 52 adjacent to the one or more probes 108. The one or more probes108 may be in contact with the interior surfaces 70 of the bore 58 toobtain the inspection data. In some embodiments, the one or more probes108 emit ultrasound signals into the first and second components 50, 52,and the one or more probes 108 receive reflected ultrasound signals.Each probe 108 may include one or more transducers. A couplant medium(e.g., water, oil, lubricant) may be disposed between the one or moreprobes 108 and the interior surfaces 70 of the bore 58 such that the oneor more probes 108 are in contact with the interior surfaces 70 via thecouplant medium. The couplant medium may be applied (e.g., injected,pumped, sprayed) to the surface of the one or more probes 108, theinterior surfaces 70 of the bore 58, or any combination thereof. Thecouplant medium may facilitate transmission of the ultrasound signalsbetween the one or more probes 108 and the interior surfaces 70 of thefirst and second components 50, 52. The one or more probes 108 emit theultrasound signals in the radial direction 73 into the first and secondcomponents 50, 52.

A processor 112 of the controller 110 may process signals based at leastin part on the received signals to generate the inspection data 114 thatmay be stored in a memory 116. The inspection data 114 may include, butis not limited to baseline data 118, inspection run data 120, and trenddata 122. The baseline data 118 may be used for comparison with laterobtained inspection run data 120 to determine any deviations from abaseline (e.g., zero reference). The baseline data 118 may be based atleast in part on a model, or the baseline data 118 may be empiricallydetermined. For example, the baseline data 118 may be empiricallydetermined from components 50, 52 of an assembled flange connection 54after manufacture or refurbishment. The inspection run data 120 is basedat least in part on signals processed by the processor 112 for aparticular inspection run, such as a re-inspection prior to installationof the first and second components 50, 52 in a second hydrocarbonextraction system. The inspection run data 120 may be compared with thebaseline data 118 to identify and evaluate any flaws (e.g., porosity,cracks, wear) of the components 50, 52. The processor 112 may generatethe trend data 122 upon comparison of one or more sets of the inspectionrun data 120 with previously obtained sets of the inspection run data120. In some embodiments, trend data 122 may be based at least in parton comparison of inspection run data 120 from different components,different hydrocarbon extraction systems, or any combination thereof.Accordingly, the trend data 122 may facilitate the identification oftrends or patterns in cracks or wear of components of the hydrocarbonextraction system.

In some embodiments, the inspection data 114 may include identifyinginformation regarding the inspected component (e.g., part number, flangeconnection identifier, RFID, installation history) and the inspectionprocess (e.g., inspection operator, date, time). Furthermore, some ofthe inspection data 114 may be stored on and/or accessed from a network123 remote from the controller 110. As may be appreciated, the network123 may facilitate the communication of inspection data 114 betweencontrollers 110 at different locations.

In some embodiments, a suspension system 125 coupled to the first probeassembly 100 moves the first probe assembly 100 in the axial direction104 within the bore 58. The first probe assembly 100 may be suspended byone or more cables 127 coupled to the suspension system 125. In someembodiments, the suspension system 125 includes one or more winches orpulleys coupled to the one or more cables 127 to facilitate movement inthe axial direction 104. The suspension system 125 may couple to thestack equipment 18 such that the one or more cables 127 are suspendedproximate to the axis 56 of the bore 58. One or more umbilical lines 131couple the first probe assembly 100 to the controller 110. Eachumbilical line of the one or more umbilical lines 131 may conveyelectrical signals, electrical power, or fluids between the controller110 and the first probe assembly 100. A connection receiver 133 of thefirst probe assembly 100 may be configured to couple the one or moreumbilical lines 131 with corresponding conduits of the first probeassembly 100 via one or more quick connections. While the suspensionsystem 125 and the controller 110 are illustrated in FIG. 4 as separatecomponents of an inspection system 129, it may be appreciated that someembodiments of the suspension system 125 may be integrated with thecontroller 110, such as being disposed within a common enclosure.

The second probe assembly 102 utilizes one or more fastener probes 124to generate inspection data regarding the plurality of fasteners 60 ofthe flange connection 54. The one or more fastener probes 124 emitultrasound signals into the fasteners 60 in the axial direction 104, andthe one or more fastener probes 124 receive reflected ultrasoundsignals. In some embodiments, the one or more fastener probes 124 emitultrasound signals in a direction substantially parallel (e.g., lessthan 30° offset) to the axial direction 104. As may be appreciated, theone or more fastener probes 124 may be in contact with a fastener 60(e.g., bolt, stud) when emitting and receiving the ultrasound signals.The couplant medium (e.g., water, oil, lubricant) may be disposedbetween the one or more fastener probes 124 and the fastener 60 suchthat the one or more fastener probes 124 are in contact with thefastener 60 via the couplant medium. The couplant medium may be applied(e.g., injected, pumped, sprayed) to the surface of the one or morefastener probes 124, the fastener 60, or any combination thereof. Thecouplant medium may facilitate transmission of the ultrasound signalsbetween the one or more fastener probes 124 and the fastener 60. In someembodiments, an operator that arranges (e.g., couples) the second probeassembly 102 to the fastener 60 may apply the couplant medium to thefastener 60. In a similar manner as discussed above with the one or moreprobes 108, the controller 110 may process signals based at least inpart on the received signals to generate the inspection data 114 thatmay be stored in the memory 116. The inspection data 114 may beassociated with each respective fastener 60 of the plurality offasteners. As discussed in detail below, some embodiments of thefastener probe 124 of the second probe assembly 102 may rotate about afastener axis to obtain the inspection data for each fastener 60.Accordingly, the inspection data 114 for each fastener 60 of the flangeconnection 54 may be obtained in series via the second probe assembly102. Multiple second probe assemblies 102 may facilitate obtaininginspection data for multiple respective fasteners 60 in parallel withone another.

FIG. 5 is perspective view of an embodiment of a second probe assembly102 coupled to a fastener 60 of a flange connection 54. The second probeassembly 102 may be a fastener probe assembly 200 configured to at leastpartially receive the fastener 60 and inspect the fastener 60 from theaxial direction 104. Each fastener 60 may be a bolt or stud that extends(e.g., axially) through the flange 62 of the first component 50 tocouple with the second component 52, as shown by the dashed lines inFIG. 5. In some embodiments, the fasteners 60 are threadably coupled to,brazed, welded, or integrally formed with either the first component 50or the second component 52. A nut 202 may be coupled (e.g., threadablycoupled) to each fastener 60 to secure the flange 62 to the secondcomponent 52, thereby forming the flange connection 54. In someembodiments, the fastener probe assembly 200 is configured to at leastpartially receive the nut 202 coupled to each fastener 60. Additionally,or in the alternative, the fastener probe assembly 200 is configured toat least partially receive a bolt head 203 of each fastener 60, where itmay be appreciated that the bolt head 203 at a first end of a fastener60 may have substantially the same geometry (e.g., hexagonal) as the nut202 coupled to an opposite second end of the fastener 60. The fasteners60 are spaced apart in the radial direction 73 from a body 204 of thefirst component 50. Each fastener connection 54 may have approximately4, 5, 6, 7, 8, 10, 12, 16, 18, 20, 24, 28, 36, or more fasteners 60 tocouple the first component 50 to the second component 52.

The fastener probe assembly 200 is configured to couple with an axialend 206 of each fastener 60. In some embodiments, an orienting surface208 of the fastener probe assembly 200 interfaces with the body 204 ofthe first component 50 when the fastener probe assembly 200 is coupledto the axial end 206 of a fastener 60. The orienting surface 208 mayenable the fastener probe assembly 200 to be consistently aligned in theradial direction 73 relative to the axis 56 of the flange connection 54when the fastener probe assembly 200 is coupled to each fastener 60.

FIG. 6 is a perspective top view of an embodiment of the fastener probeassembly 200. The fastener probe 124 is configured to emit ultrasoundsignals into the axial end 206 of each fastener 60. The fastener probe124 is coupled to a disc 210 that rotates about a fastener axis 212, asshown by arrow 213. As the disc rotates 210, a cable 214 that couplesthe fastener probe 124 to the controller 110 may coil or uncoil within ahousing 216. The housing 216 is configured to at least partially receivethe fastener 60. For example, the housing 216 may be configured tointerface with the driving surfaces 215 of the nut 202 or the bolt head203 of the fastener 60 to maintain the orientation of the housing 216about the fastener axis 212 when the fastener probe assembly 200 iscoupled to the fastener 60. In some embodiments, multiple (e.g., 2, 3,4, 5, 6, 7, 8, 9, 10, or more) fastener probes 124 are coupled to thedisc 210. While the fastener probe 124 of the fastener probe assembly200 illustrated in FIG. 6 emits ultrasound signals into and receivesreflected ultrasound signals from the same axial end 206 of the fastener60, other embodiments of the fastener probe assembly 200 may utilizeseparate transmitters and receivers at opposite ends of the fastener 60for through transmission of the ultrasound signals through the fastener60.

An encoder (e.g., rotary encoder) 218 coupled to the disc 210 and to thecontroller 110 enables the controller 110 to determine thecircumferential position of the one or more fastener probes 124 aboutthe fastener axis 212 as the disc 210 rotates during a fastenerinspection. In some embodiments, the rotary encoder is a magnetic bandring encoder. Accordingly, the encoder 218 and the inspection dataenables the controller 110 to identify the circumferential and axiallocation of any flaws (e.g., porosity, cracks, wear) identified in thefasteners 60. In some embodiments, one or more pins 217 (e.g., springball plungers) of the housing 216 may radially interface with the nut202 or bolt head 203 of the fastener 60 when the fastener probe assembly200 is coupled to the fastener 60. Ends 219 of the pins 217 (e.g.,spring ball plungers) may be biased into contact with the fastener 60,thereby centering the one or more fastener probes 124 about the fasteneraxis 212. FIG. 6 illustrates the one or more biased pins 217 (e.g.,spring ball plungers) as external to the housing 216, however, the oneor more biased pins may be installed within the housing 216 throughretention recesses 221 that may extend through the housing 216. A lockfeature 223 may move in a radial direction 225 to interface with the nut202 or bolt head 203 of the fastener 60 and maintain the orientation ofthe housing 216 relative to the fastener 60. In some embodiments, thelock feature 223 is a lever, such that rotation in a direction 227 aboutthe radial direction 225 engages or disengages the lock feature 223 withthe fastener 60, thereby maintaining the orientation of the housing 216relative to the fastener 60. A cover 229 may be positioned over the oneor more fastener probes 124 to protect the one or more probes 124 fromunintended physical contact with the environment. Moreover, the cover229 may facilitate manual positioning of the fastener probe assembly 200on the fastener 60 to be inspected.

In some embodiments as illustrated in FIG. 5, the orienting surface 208interfaces with the body 204 of the first component 50 so that thefastener probe assembly 200 may start the inspection of each fastener 60from substantially the same orientation and position relative to theaxis 56. Thus, the rotary encoder 218 may facilitate the determinationof the position of the fastener probe 124 relative to the fastener axis212 for each fastener 60, and the orienting surface 208 facilitates thedetermination of the position of the fastener probe assembly 200relative to the axis 56 of the flange connection 54. Inspection of eachfastener in a similar manner with the fastener probe assembly 200 andthe fastener probe 124 in consistent orientations for each fastener 60enables the inspection data for each fastener 60 to be readily comparedwith one another.

Identification of each fastener 60 may aid the comparison of inspectiondata for each fastener 60 to other fasteners 60 of the flange connection54. Additionally, identification of each fastener 60 may enable thecomparison of inspection data for each fastener 60 to itself over aservice life of the respective fastener 60. FIG. 7 is a cross-sectionalview of an embodiment of the fastener probe assembly 200 and a fastener220 with an identifier 222. The identifier 222 may include, but is notlimited to a bar code, a part number, a unique geometry, an RFID tag orchip, or any combination thereof. In some embodiments, a sensor (e.g.,scanner, chip reader) 224 of the fastener probe assembly 200 maydetermine the identity of the fastener 220 via the identifier 222. Theidentifier 222 may be disposed in a centering feature of the fastener220 along the fastener axis 212. In some embodiments, the fastener probe124 is arranged eccentrically in the disc 210 about the fastener axis212 so that the fastener probe 124 does not emit ultrasound signalsdirectly through the identifier 222.

Mounted eccentrically about the fastener axis 212, the fastener probe124 emits ultrasound signals through a section of the fastener 220, asshown by the lines 226. FIG. 8 is a cross-sectional view of anembodiment of a fastener probe assembly 200 with the fastener probe 124mounted to the disc 210 concentric with the fastener axis 212. Forexample, FIG. 8 illustrates the fastener probe assembly 200 coupled to afastener 230 (e.g., bolt) of an H-4® subsea connector without anidentifier 222 embedded in along the fastener axis 212. Rotation of thediscs 210 about the fastener axes 212 illustrated in FIGS. 7 and 8sweeps the ultrasound signals through substantially the entirerespective fastener 220, 230. The controller 110 may control themovement of the disc 210 in direction 213 about the fastener axis 212based at least in part on feedback from the encoder 218.

In some embodiments, the fastener probe 124 is a phased array ofultrasound transducers controlled by the controller 110. The controller110 may control the phased array fastener probe 124 to adjust thecoverage depth and/or the resolution of the ultrasound signals toidentify flaws (e.g., porosity, cracks, wear) of the fastener 220, 230.In particular, the fastener probe 124 may be controlled to identify andevaluate flaws in threads 228 of the fastener 220, 230.

FIG. 9 is an embodiment of a method 240 for inspecting fasteners of anassembled flange connection of an assembled stack of components. Theassembled stack of components is removed (block 242) from a system(e.g., hydrocarbon extraction system). The assembled stack may includetwo or more components coupled to one another via a flange connection asdiscussed above. For example, components of the assembled stack mayinclude, but are not limited to, a lower marine riser package, one ormore blowout preventers (BOPs), a subsea manifold, production trees, anH-4® subsea connector, or any combination thereof. In some embodiments,the assembled stack is removed from a subsea environment to the surfaceof a drilling rig or a ship. Once removed from the system, the fastenerprobe assembly is coupled (block 244) to a fastener (e.g., body, bolthead, nut) of an assembled flange connection. As discussed above, thecouplant medium may be applied to the fastener when the fastener probeassembly is coupled (block 244) to the fastener, such that the one ormore probes of the fastener probe assembly are in contact with thefastener via the couplant medium. Coupling the fastener probe assemblymay orient the fastener probe assembly in a consistent orientationrelative to the axis of the assembled flange connection. Additionally,the fastener probes of the fastener probe assembly are interfaced (block246) with the fastener to be inspected. For example, the fastener probesinterface with an axial end of the fastener. As discussed above, thefastener probes may include, but are not limited to ultrasound probesthat are configured to emit and receive ultrasound signals. Moreover,each of the one or more ultrasound probes may be a phased array ofultrasound transducers.

The fastener probe is moved about the axis of the fastener whileemitting ultrasound signal to inspect (block 248) the fastener. Asdiscussed herein, the fastener probe assembly is configured to inspecteach fastener of a flange connection without previously disassemblingthe fastener from the flange connection. The controller coupled to thefastener probe assembly stores (block 250) the inspection run datagenerated during the inspection (block 248). The stored inspection datamay identify features of portions of the fastener of the inspectedflange connection. The controller may compare (block 252) the inspectionrun data to baseline data. The comparison may enable the controller oran operator to determine (node 254) whether the fastener passesinspection. If the fastener does not pass inspection, the non-compliantfastener may be replaced (block 256). If the fastener does passinspection or the fastener is replaced, then the controller or theoperator determined (node 258) whether there are more fasteners of theflange connection to be inspected. As discussed above, each flangeconnection may have 4, 8, 12, 24, 36, or more fasteners, and thefasteners may be inspected in series or in parallel. If there are morefasteners to inspect, then the fastener probe assembly is coupled (block244) to another fastener that has not yet been inspected. If there areno more fasteners to be inspected, then the assembled stack ofcomponents with the inspected fasteners of the flange connection may beinstalled (block 260) into another system.

Traditionally, the components of a flange connection are disassembledand each of the fasteners is removed for penetrant or magnetic particleinspection. Accordingly, the method 240 enables the inspection offasteners of a flange connection without previously disassembling theflange connection, thereby reducing the inspection time and inspectioncosts. The fasteners that pass inspection are not removed from theflange connection. In some embodiments, only fasteners that do not passthe inspection are removed from the flange connection. Moreover,inspecting the fasteners of assembled flange connections may reduce thewear on the fasteners from unnecessarily disassembly and reassembly.

This written description uses examples to disclose the embodiments,including the best mode, and also to enable any person skilled in theart to practice the present disclosure, including making and using anydevices or systems and performing any incorporated methods. Thepatentable scope of the present disclosure is defined by the claims, andmay include other examples that occur to those skilled in the art. Suchother examples are intended to be within the scope of the claims if theyhave structural elements that do not differ from the literal language ofthe claims, or if they include equivalent structural elements withinsubstantial differences from the literal language of the claims.

The invention claimed is:
 1. A fastener probe assembly comprising: adisc configured to rotate about a first axis of a fastener; anultrasound probe coupled to the disc, wherein the ultrasound probe isconfigured to interface with an axial end of the fastener, to emitultrasound signals into the axial end of the fastener, and to receivethe ultrasound signals from the fastener, wherein the ultrasound probeis configured to be located between the disc and the fastener; and anencoder configured to determine a circumferential position of theultrasound probe about the first axis of the fastener during aninspection of the fastener.
 2. The fastener probe assembly of claim 1,comprising a housing configured to at least partially receive the axialend of the fastener and to interface with the fastener to align thefirst axis of the fastener with a second axis of the disc.
 3. Thefastener probe assembly of claim 2, wherein the housing comprises amanual lock feature configured to maintain an orientation of the housingrelative to the fastener.
 4. The fastener probe assembly of claim 2,wherein the housing comprises a plurality of biased pins configured tointerface with driving surfaces of the fastener to maintain anorientation of the housing relative to the fastener.
 5. The fastenerprobe assembly of claim 1, wherein the ultrasound probe is eccentricallymounted to the disc and the ultrasound probe is configured toeccentrically rotate about the first axis.
 6. The fastener probeassembly of claim 1, wherein the controller is configured to control therotation of the disc about the first axis of the fastener.
 7. Thefastener probe assembly of claim 6, wherein the controller is configuredto identify the at least one flaw in the fastener based at least in parton the received ultrasound signals.
 8. The fastener probe assembly ofclaim 1, wherein the ultrasound probe comprises a phased array ofultrasound transducers coupled to the disc.
 9. The fastener probeassembly of claim 1, comprising a controller configured to: receiveinspection data indicative of the ultrasound signals received from thefastener by the ultrasound probe, compare the received inspection datawith baseline data associated with the fastener, and determine, based onthe comparison between the inspection data and the baseline data, anaxial location and/or a circumferential location of at least one flaw inthe fastener.
 10. A system comprising: a probe assembly comprising adisc, a housing and one or more probes, wherein the probe assembly isconfigured to be coupled to a fastener of an assembled connection, andthe housing is configured to at least partially receive an axial end ofthe fastener, wherein the disc is configured to rotate about a firstaxis of the fastener and the ultrasound probe is configured to belocated between the disc and the fastener, wherein the probe assembly isconfigured to emit ultrasound signals into the axial end of thefastener, and to receive the ultrasound signals from the fastener; and acontroller coupled to the probe assembly, and configured to: receiveinspection data indicative of the ultrasound signals received from thefastener by the probe assembly, and compare the received inspection datawith baseline data associated with the fastener, determine, based on thecomparison between the inspection data and the baseline data, an axiallocation and/or a circumferential location of at least one flaw in thefastener.
 11. The controller of claim 10, wherein the controller isconfigured to control a circumferential movement of the one or moreprobes of the probe assembly about an axis of the fastener.
 12. Thecontroller of claim 11, wherein the controller is configured todetermine a location of a flaw within the fastener based at least inpart on the received ultrasound signals and feedback from a rotaryencoder, wherein the feedback from the rotary encoder is based on thecircumferential movement of the one or more probes of the probeassembly.
 13. An inspection method comprising: coupling a probe assemblyto a fastener of an assembled connection of an assembled stack ofcomponents, the probe assembly includes a disc and a housing, whereinthe housing of the probe assembly is configured to at least partiallyreceive the fastener, wherein the probe assembly is coupled to the discand configured to interface with an axial end of the fastener, whereinthe disc is configured to rotate about a first axis of the fastener andthe ultrasound probe is configured to be located between the disc andthe fastener; emitting, by the probe assembly ultrasound signals intothe axial end of the fastener; receiving, by the probe assembly, theultrasound signals from the fastener; receiving, by a controller coupledto the probe assembly, inspection data indicative of the ultrasoundsignals received from the fastener by the probe assembly, comparing, bythe controller, the received inspection data with baseline dataassociated with the fastener, and determining, by the controller, anaxial and/or a circumferential location of at least one flaw in thefastener, wherein the determining is based on the comparison between theinspection data and the baseline data.
 14. The inspection method ofclaim 13, comprising rotating the probe assembly about an axis of thefastener while emitting the ultrasound signals from the fastener probeassembly and receiving the ultrasound signals at the fastener probeassembly.
 15. The inspection method of claim 13, comprising centeringthe housing of the probe assembly and the fastener probe assembly aboutan axis of the fastener, wherein centering the housing comprises atleast one of interfacing biased pins with the fastener and engaging alock feature.
 16. The inspection method of claim 13, comprisingidentifying flaws in the fastener of the assembled connection based atleast in part on the received ultrasound signals without disassemblingthe assembled connection.
 17. The inspection method of claim 13,comprising certifying the assembled stack of components for installationin a hydrocarbon extraction system without disassembling the assembledflange connection.